Par 13-1 Page 55 CHAPTER 13. STATISTICAL ANALYSIS TASKING OPTIMIZATION
13-1. GENERAL. Statistical Analysis Tasking Optimization (SATO) is a term to describe an original equipment manufacturer (OEM)/type certificate holder (TCH) customized program for optimization of scheduled maintenance. It is data driven, combining data for model-specific fleets from multiple operators that use the type of aircraft under a variety of operating conditions and environments. Its intention is to use a larger fleet sampling data to optimize tasking intervals in operators’ maintenance programs. SATO is not intended to replace an operator’s Reliability Program (if applicable). Its use by operators will be voluntary. OEMs/TCHs that wish to offer SATO programs must design a framework for its operation. The OEM/TCH will work with the appropriate Aircraft Evaluation Group (AEG) to evaluate the program at the Maintenance Review Board (MRB) level.
13-2. APPLICABILITY. An OEM/TCH SATO program should contain these minimum elements:
a. A delivery system of data from the operator to the OEM in an ATA SPEC 2200 format (or equivalent).
b. An in-service data program to catalog the data into a useable form.
c. An aircraft reliability management database. The OEM/TCH must have a quality assurance system that ensures the data are clean and valid before accomplishing the engineering analysis.
d. A statistical model that will optimize the data.
13-3. OPERATOR PARTICIPATION.
a. Prerequisites for Participation. If an operator wishes to participate in an OEM/TCH SATO program, the OEM/TCH will have to accept it. This means the operator must meet the OEM/TCH prerequisites that may include supplying specific historical data about their fleet in a format acceptable to the OEM/TCH program. Complete (from birth) data would be the best;
however, that will not always be possible. The OEM/TCH program will set a baseline of minimum data.
b. Maintenance Planning Document (MPD). Data will be combined with other participant operators’ data to “optimize” the MPD by including a larger sample of data. The AEG chairperson or the designee for the affected aircraft will review the OEM/TCH recommendation for an optimized task and resolve any issues. The principal inspectors (PI) who have operators with affected aircraft will have an opportunity to comment on the proposed optimized task before final consideration. When satisfied with the technical merits, the AEG will send the OEM/TCH recommendation to AFS-302 for policy review and final concurrence. The OEM/TCH will then distribute the accepted recommendation to all participating operators. Only operators participating in the SATO program will be allowed to use the optimized MPD. The participating operators would then incorporate the new revised MPD task into their maintenance program and submit the revision to the PI.
Appendix 1 APPENDIX 1. ACRONYM/ABBREVIATION LISTING FOR THE MRB REPORT The following is a recommended listing of acronyms and abbreviations that may be contained in each MRB Report.
AC Advisory Circular ACO Aircraft Certification Office AD Accidental Damage/Airworthiness Directive ADR Accidental Damage Rating AEG Aircraft Evaluation Groups AEG-BOS Boston-AEG, Engines, Propellers AEG-DFW Dallas Ft. Worth-AEG, Rotorcraft AEG-LGB Long Beach-AEG, Transport Aircraft AEG-MKC Kansas City-AEG, Small Airplane AEG-SEA Seattle-AEG, Transport Aircraft AFS Flight Standards Services AEP Age Exploration Program AFRP Aramid Fiber Reinforced Plastic ALI Airworthiness Limitations AMM Aircraft Maintenance Manual AMOC Alternate Means of Compliance ATA Air Transport Association of America, Inc.
CAM Canadian Airworthiness Manual CAA Civil Airworthiness Authority CFR Code of Federal Regulations CFRP Carbon Fiber Reinforced Plastic CMCC Certification Maintenance Coordination Committee CMM Component Maintenance Manual CMO Certificate Management Office CMR Certification Maintenance Requirement CP Corrosion Program CPCP Corrosion Prevention and Control Program DAH Design Authority Holder DET Detailed Inspection DIS Discard DSO Design Service Objective DTA Design Tolerance Assessment DTR Damage Tolerance Rating DVI Detailed Visual Inspection DY Daily EASA European Aviation Safety Agency EAPAS Enhanced Airworthiness Program for Airplane Systems ECO Engine Certification Office ED Environmental Deterioration Page 1
Appendix 1 EDR Environmental Deterioration Rating EICAS Engine Indicating and Crew Alerting System EROPS Extended Range Operations ETOPS Extended Two Engine Operations EWIS Electrical Wiring Interconnection System EZAP Enhanced Zonal Analysis Procedure FAA Federal Aviation Administration FAR Federal Aviation Regulations FC Functional Check FCK Functional Check FD Fatigue Damage FEC Failure Effect Category FH Flight Hours FLT Flight FMEA Failure Mode and Effects Analysis FOEB Flight Operations Evaluation Board FSDO Flight Standards District Office FTS Fuel Tank Safety GFRP Glass Fiber Reinforced Plastic GV General Visual GVI General Visual Inspection HIRF High Intensity Radiated Fields ICA Instructions for Continuing Airworthiness ICAO International Civil Aviation Organization IP Issue Paper ISC Industry Steering Committee IMRBPB International Maintenance Review Board Policy Board JAA Joint Aviation Authorities JAR Joint Airworthiness Requirement JOEB Joint Operations Evaluation Board L/HIRF Lightning/High Intensity Radiated Field LU Lubrication Task MEA Maintenance Engineering Analysis MMEL Master Minimum Equipment List MFG Manufacturer MEL Minimum Equipment List MTB Maintenance Type Board Process MTBR Maintenance Type Board Process Report MPD Maintenance Planning Data Document MPIG Maintenance Program Industry Group MPP Maintenance Program Proposal MRB Maintenance Review Board MRBPB Maintenance Review Board Policy Board MRB Report Maintenance Review Board Report Page 2
Appendix 1 MSC Maintenance Steering Committee MSG-1 Maintenance Steering Group - 1st Task Force MSG-2 Maintenance Steering Group - 2nd Task Force MSG-3 Maintenance Steering Group - 3rd Task Force MSI Maintenance Significant Item MTBF Mean Time Between Failure MTBUR Mean Time Between Unscheduled Removal MWG Maintenance Working Group NDI Non-destructive Inspection NDT Non-destructive Test OEM Original Equipment Manufacturer OPC Operational Check PI Principal Inspector PMMEL Proposed Master Minimum Equipment List PPH Policy and Procedures Handbook PSE Principal Structural Element R/I Remove and Install RF Radiated Frequency RMP Recommended Maintenance Process (RMP) RS Restoration Task RST Restoration SATO Statistical Analysis Tasking Optimization SDI Special Detailed Inspection SID Supplemental Inspection Document SFAR Special Federal Aviation Regulation SIP Structural Inspection Procedure SSA System Safety Assessment SSI Structural Significant Item SSID Supplemental Structural Inspection Document SVC Service Task STWG Structures Working Group SWG Structures Working Group TCH Type Certificate Holder TBD To Be Determined TCDS Type Certificate Data Sheet UV Ultra-Violet VC Visual Check Task VCK Visual Check WG Work Group ZA Zonal Analysis ZIP Zonal Inspection Program ZLWG Zonal Working Group ZWG Zonal Working Group
Appendix 2 APPENDIX 2. IP 44 DEFINITIONS
a. Confidence Level. The likelihood that the overall fleet performance lies within the range specified by the sample fleet performance. The confidence level is usually expressed as a percentage.
b. Nonroutine Task. A task is nonroutine when it is not a planned/scheduled task coming from the operator’s/manufacturer’s maintenance program.
c. Nonmetallics. Any structural material made from fibrous or laminated components bonded together by a medium. Materials such as graphite epoxy, boron epoxy, fiberglass, kevlar epoxy, acrylics and the like are nonmetallics. Nonmetallics include adhesives used to join other metallic or nonmetallic structural materials.
d. Line Maintenance. Routine check, inspection and malfunction rectification performed en-route and at base stations during transit, turn-around or night stop.
e. Pilot Report (also known as PIREP). Suspected or known malfunctions, or unsatisfactory conditions that are entered by the flightcrew into the aircraft log and require maintenance action.
f. Qualified FAA MRB Chairperson. An Airworthiness inspector with working knowledge of the Maintenance Review Board (MRB) process must have system/structures training on particular aircraft and have MSG formal training.
g. Unscheduled Maintenance. Maintenance performed to restore an item to a satisfactory condition by providing correction of a known or suspected malfunction and/or defect.
h. Evolution/Optimization. Task through the management of data is a means to assure the continued applicability and effectiveness of the task while improving the integrity of the process.
i. Risk Management. The systematic application of management policies, procedures, and practices to the tasks of identifying, analyzing, evaluating, treating and monitoring risk.
j. Safety Management. The application of engineering and management principles, criteria and techniques to optimize safety. It is an integrated and comprehensive engineering effort.
k. Structural Significant Items (SSI). Any detail, element, or assembly that contributes significantly to carrying flight, ground, pressure or control loads, and whose failure could affect the structural integrity necessary for the safety of the aircraft.
Appendix 3 APPENDIX 3. POLICIES AND PROCEDURES HANDBOOK FORMAT This appendix intends to provide standardized and harmonized policy in the development of a proper policy and procedures handbook (PPH). It is encouraged that all industry applicant’s PPH documents be developed containing the same basic data and information, as applicable, to provide for a complete, consistent, and quality process.
Regulatory authority and industry experience has indicated that the following information is expected in each PPH, as applicable, for the successful latest version of the Maintenance Steering Group process and development of a Maintenance Review Board Report:
SCHEDULED MAINTENANCE DEVELOPMENT Contents of PPH I Approval & Acceptance Lette rs or Signature Page II Record of Revisions III List of Effective Pages IV History of Changes Table of Contents List of Figures List of Tables Highlights of Significant PPH Changes
1. Introduction
1.1 Purpose
1.2 Background
1.3 Scope & Objective
1.4 Regulatory Requirements
1.5 MSG Guidelines
1.6 Revision Process Policy
1.7 Temporary Revisions Process
1.8 Program Organization Program Work Schedule Page 1
Appendix 3
1.9 Main Principles and Design Standards
1.10 Aircraft Utilization Assumptions
1.11 Establishing Task Intervals (Frequencies)
1.11.1 Systems & Powerplants Task Interval Determination
1.11.2 Zonal Inspection Task Interval Determination
1.11.3 Structures Task Interval Determination
1.11.4 Task Review Procedures
1.11.4.1 General
1.11.4.2 Factors to be considered
1.11.4.3 ISC & MRB Responsibilities
1.11.4.4 Manufacturer Responsibilities
1.11.4.5 Evaluation Criteria
1.11.4.6 Lubrication Tasks
1.11.4.7 Servicing Tasks
1.11.4.8 Operational Check
1.11.4.9 Inspection Tasks (General Visual, Detailed, Special Detailed)
1.11.4.10 Functional Check
1.11.4.11 Restoration or Discard
1.11.4.12 Structure/Zonal Inspections
1.11.4.13 Task Interval Review Report
1.12 IP 44 MRB Optimization Process
2. Organization and Administration
2.1 Industry Participation
2.1.1 General
2.1.2 Intellectual Property Management Page 2
Appendix 3
2.1.3 Communications, Inte rnal and External
2.1.4 Industry Steering Committee (ISC)
2.1.5 Working Groups (WG)
2.1.6 OEM/TCH
2.1.7 Partners, Suppliers & Vendors
2.1.8 Certification and Design personnel
2.2 FAA & Other Regulatory Authority Participation & Functions
2.2.1 General
2.2.2 Regulatory Authority Ma intenance Review Board
2.2.3 Regulatory Authority Members and Advisors
2.2.4 Foreign Regulatory Authorities
2.2.5 Aircraft Certification office personnel
2.3 Documentation
2.3.1 MRB Report Revisions Prior to Entry into Service
2.3.2 Latest version of MSG Analysis Procedure
2.4 Organization of Meetings
2.4.1 ISC & WG Meeting Reports
2.4.2 ISC & WG Action Item Lists
2.4.2 Acceptance & Timely Distribution of Reports and Lists
2.5 Meeting Reports
2.5.1 Standardization and Harmonization of Required Data for WG Meeting Reports
2.5.2 Standardization and Harmonization of Required Data for ISC Meeting Reports
2.6 Supplemental Presentations Page 3
Appendix 3
3. Systems and Powerplant Analysis Procedures
3.1 General
3.1.1 Handling and Tracking of Task Transfers to Zonal
3.1.2 Handling and Tracking of Task Transfers amongst Systems and Powerplant WGs
3.2 Procedural Steps
3.2.1 Maintenance Significant Item (MSI) List (Appendix E)
3.2.2 Maintenance Significant Item Selection Form
3.2.3 The Systems Functional Description (SDF) Form
3.2.4 Component Supplier & Maintainability and Reliability Data (MDR) Form
3.2.5 Design Features
3.2.6 The Functional Failure Analysis (FFA) Form
3.2.7 The Failure Effect Questions (FEQ) Form
3.2.8 The Task Selection Questions (TSQ) Form
3.2.9 Task Summary
3.3 Analysis Forms
3.4 Responsibilities
3.4.1 OEM/TCH
3.4.2 Partners, Suppliers & Vendors
3.4.3 Working Groups
3.4.4 Industry Steering Committee
3.5 Analysis Guidelines
3.6 Lightning/HIRF Protection System Analysis Procedures
3.6.1 Introduction
3.6.2 Propose for Consideration of Process Revision
3.6.3 Proposal Page 4